Exhaust System - Repair BMW Z4 E85/E86

18 00 020 Removing and installing complete exhaust system (M54)

Special tools required

1. 31 2 220

Support exhaust system with jack and special tool 31 2 220 and secure against falling out.

Scheme 1

Lift out expansion rivet (1).

Release screws and remove heat shield (2).

Scheme 2

Release nuts (1) and remove connecting plate (2).

Installation

Replace self-locking nuts.

Coat threads with copper paste.

Scheme 3

Installation

Replace both seals (1).

Scheme 4

Note. The reinforcement plate (1) is connected via rubber mounts to the exhaust system and can remain on the exhaust system during removal.

Release screws on reinforcement plate (1). See 51 71 390 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE .

Release screws and remove body reinforcement strut (2). See 51 71 482 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TENSION STRUT .

Release nuts on rubber mount of rear muffler (3) on left and right.

Lower exhaust system with lifter and remove.

Scheme 5

18 12 030 Replacing final muffler

Special tools required

1. 00 2 210

Note. Illustration shows exhaust system removed.

Determining cutting line

Carry over pipe length of new rear muffler to installed rear muffler (1).

Marking cutting line.

Scheme 6

Cut exhaust pipes with special tool 00 2 210 at marked points and deburr.

Scheme 7

Release screws and nuts, remove reinforcement plate (1). See 51 71 390 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE .

Release screws and remove body reinforcement strut (2). See 51 71 482 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TENSION STRUT .

Release nuts on rubber mount of rear muffler (3) on left and right and remove rear muffler (3).

Installation

Fit rubber mount of rear muffler on new rear muffler.

Scheme 8

Installation

Connect new rear muffler and front muffler by means of clamping sleeves.

Cutting point is in middle of clamping sleeve.

Align exhaust system and clamping sleeves so that there is sufficient distance to the adjoining components.

Scheme 9

Installation

Check position of tailpipes (1) to body cutout.

Tighten down screws of clamping sleeves.

Scheme 10

18 12 040 Removing and installing/replacing front muffler (M54)

Special tools required

1. 00 2 210

Note. Illustration shows exhaust system removed.

Determining cutting line

Carry over pipe length of new front muffler to installed front muffler (1).

Marking cutting line.

Scheme 11

Cut exhaust pipes with special tool 00 2 210 at marked points and deburr.

Scheme 12

Release nuts (1) and remove connecting plate (2).

Installation

Replace self-locking nuts.

Coat thread with copper paste.

Scheme 13

Installation

Replace both seals (1).

Scheme 14

Installation

Connect new front muffler and rear muffler by means of clamping sleeves.

Cutting point is in middle of clamping sleeve.

Align exhaust system and clamping sleeves so that there is sufficient distance to the adjoining components.

Scheme 15

18 40 030 Removing and installing/replacing both exhaust manifolds (M54)

Necessary preliminary tasks

1. Secure engine in installation position . See «11 00 050 REMOVING AND INSTALLING ENGINE (M54)»(/bmw/z4/e85e86-2002-2005/remont/mechanical/#engine-repair-m54__11-00-050-removing-and-installing) .
2. Remove front engine underguard
3. Remove reinforcement plate . See «51 71 390 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-71-390-removing-and-installingreplacing) .
4. Remove entire exhaust system . See «18 00 020 Removing And Installing Complete Exhaust System (M54)»(/bmw/z4/e85e86-2002-2005/remont/exhaust/#exhaust-system-repair__18-00-020-removing-and-installing) .
5. Remove bracket between exhaust manifold and transmission
6. Detach grounding cable from body
7. Remove right engine support arm with engine mount.
8. Release nuts on heat shield at bottom
9. Remove right tension strut . See «51 71 371 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-71-371-removing-and-installingreplacing) .
10. Remove air pump . See «11 72 000 REMOVING AND INSTALLING/REPLACING AIR PUMP»(/bmw/z4/e85e86-2002-2005/remont/mechanical/#engine-repair-m54__11-72-000-removing-and-installingreplacing) .
11. Release heat shield at top and remove

Note. The oxygen sensors are in danger of being damaged when the exhaust manifolds are removed and installed.

Remove oxygen control sensors. See 11 78 513 REPLACING BOTH OXYGEN CONTROL SENSORS .

Remove cover from injection valves.

Note. Do not mix up oxygen monitor sensors for cylinders 1 to 3 and 4 to 6 at plug connection to wiring harness.

Mark plug connections.

Unclip the cable from the retainer. Disconnect plug connection. Unclip cable on rear side of engine from cable guide.

Remove oxygen monitor sensor from cylinders 1 to 3 from above. See 11 78 611 REPLACING OXYGEN MONITOR SENSOR .

Scheme 16

Note. Rear exhaust manifold with catalytic converter can only be removed after front exhaust manifold with catalytic converter has first been removed.

Remove front exhaust manifold with catalytic converter. See 18 40 050 Removing And Installing/Replacing Front Exhaust Manifold (M54) .

Remove oxygen monitor sensor from cylinders 4 to 6. See 11 78 612 REPLACING OXYGEN MONITOR SENSOR .

Unscrew nuts.

Remove exhaust manifold (1).

Installation

Clean sealing faces, replace gaskets.

Coat threads with copper paste.

Replace nuts.

Tightening torque, see 11 62 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 17

18 40 050 Removing and installing/replacing front exhaust manifold (M54)

Necessary preliminary tasks

1. Secure engine in installation position. See «11 00 050 REMOVING AND INSTALLING ENGINE (M54)»(/bmw/z4/e85e86-2002-2005/remont/mechanical/#engine-repair-m54__11-00-050-removing-and-installing) .
2. Remove front splash guard.
3. Remove reinforcement plate. See «51 71 390 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-71-390-removing-and-installingreplacing) .
4. Remove complete exhaust system. See «18 00 020 Removing And Installing Complete Exhaust System (M54)»(/bmw/z4/e85e86-2002-2005/remont/exhaust/#exhaust-system-repair__18-00-020-removing-and-installing) .
5. Remove bracket between exhaust manifold and transmission.
6. Detach grounding cable from body.
7. Remove right engine support arm with engine mount.
8. Release nuts on heat shield at bottom.
9. Remove right tension strut. See «51 71 371 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair__51-71-371-removing-and-installingreplacing) .
10. Remove air pump. See «11 72 000 REMOVING AND INSTALLING/REPLACING AIR PUMP»(/bmw/z4/e85e86-2002-2005/remont/mechanical/#engine-repair-m54__11-72-000-removing-and-installingreplacing) .
11. Release heat shield at top and remove.

Note. The oxygen sensors are in danger of being damaged when the exhaust manifolds are removed and installed.

Remove front oxygen control sensor. See 11 78 513 REPLACING BOTH OXYGEN CONTROL SENSORS .

Remove cover from injection valves.

Note. Do not mix up oxygen monitor sensors for cylinders 1 to 3 and 4 to 6 at plug connection to wiring harness.

Mark plug connections.

Unclip the cable from the retainer. Disconnect plug connection. Unclip cable on rear side of engine from cable guide.

Remove oxygen monitor sensor from cylinders 1 to 3 from above. See 11 78 611 REPLACING OXYGEN MONITOR SENSOR .

Scheme 18

Unscrew nuts.

Remove exhaust manifold (1).

Installation

Clean sealing faces, replace gaskets.

Coat threads with copper paste.

Replace nuts.

Tightening torque, see 11 62 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 19

18 40 060 Removing and installing/replacing rear exhaust manifold (M54)

Rear exhaust manifold with catalytic converter can only be removed after front exhaust manifold with catalytic converter has first been removed.

Procedure is described in 18 40 030 Removing And Installing/Replacing Both Exhaust Manifolds (M54) .

See also:
• 51 71 390 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE
• 51 71 482 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT TENSION STRUT
• 11 00 050 REMOVING AND INSTALLING ENGINE (M54)
• 51 71 371 REMOVING AND INSTALLING/REPLACING TENSION STRUT ON LEFT OR RIGHT
• 11 72 000 REMOVING AND INSTALLING/REPLACING AIR PUMP
• 11 78 513 REPLACING BOTH OXYGEN CONTROL SENSORS
• 11 78 611 REPLACING OXYGEN MONITOR SENSOR
• 11 78 612 REPLACING OXYGEN MONITOR SENSOR
• ENGINE - TIGHTENING TORQUES
• 18 00 020 Removing And Installing Complete Exhaust System (M54)
• 18 40 050 Removing And Installing/Replacing Front Exhaust Manifold (M54)
• 18 40 030 Removing And Installing/Replacing Both Exhaust Manifolds (M54)